how to replace motorcycle handlebars

Daniel Parker

3 min read

·

31-01-2025

1

0

Share

Meta Description: Learn how to replace your motorcycle handlebars safely and efficiently! This comprehensive guide covers tools, techniques, and crucial safety tips for a successful handlebar swap. From choosing the right handlebars to tightening torque specs, we've got you covered. Upgrade your riding experience today!

Choosing Your New Handlebars

Before you even begin the replacement process, selecting the right handlebars is crucial. Consider these factors:

• Compatibility: Ensure the handlebars are compatible with your specific motorcycle model and year. Check the manufacturer's specifications and consult your motorcycle's service manual. Incorrect fitment can lead to safety hazards.
• Style and Rise: Different handlebar styles (clip-ons, drag bars, ape hangers, etc.) drastically affect riding posture and control. Choose a style that suits your riding preference and body type. "Rise" refers to the height of the handlebars; higher rise generally means a more upright riding position.
• Material: Handlebars are typically made of steel, aluminum, or chrome-moly. Aluminum handlebars are lighter, while steel offers more strength. Consider the weight and durability requirements for your riding style.
• Width: Handlebar width significantly impacts handling and comfort. Wider handlebars offer greater leverage but can make maneuvering at low speeds more challenging.

Remember to always check your local laws and regulations concerning handlebar height and modifications before making any changes.

Tools and Materials You'll Need

To replace your motorcycle handlebars, you'll need the following tools and materials:

• New handlebars: Make sure these are compatible with your bike!
• Socket wrench set: This should include the correct size sockets for your handlebar clamps and other fasteners.
• Torque wrench: Essential for tightening bolts to the manufacturer's specifications. Over-tightening can damage components. Under-tightening can lead to dangerous looseness.
• Allen wrenches: Many handlebars and controls use Allen bolts.
• Pliers: Needle-nose pliers can be helpful for reaching tight spots.
• Wire cutters/strippers: If you're rerouting any cables or wires.
• Shop rags or paper towels: For cleaning up and protecting surfaces.
• Owner's manual: To reference torque specifications and diagrams.
• Optional: Penetrating oil: Can help loosen stubborn bolts.

Step-by-Step Guide to Replacing Motorcycle Handlebars

This guide assumes a basic level of mechanical aptitude. If you're uncomfortable working on your motorcycle, take it to a qualified mechanic.

1. Preparation:

• Disconnect the battery: This is a crucial safety step to prevent short circuits.
• Remove fairings or other components: Access to the handlebar clamps may require removing body panels. Refer to your owner's manual for guidance.

2. Remove the Old Handlebars:

• Loosen the handlebar clamps: Use the appropriate socket wrench to carefully loosen the bolts securing the handlebars to the triple clamps. Don't remove them completely yet.
• Disconnect cables and wiring: Disconnect the throttle, clutch, brake, and other control cables and wiring harnesses. Take photos or make notes to ensure correct reassembly.
• Remove the handlebars: Once the clamps are loosened, carefully remove the handlebars. They may be slightly tight, so use gentle but firm force.

3. Install the New Handlebars:

• Position the new handlebars: Align the new handlebars within the triple clamps, ensuring they are centered and level.
• Secure the handlebar clamps: Tighten the clamp bolts to the manufacturer's specified torque settings. Use a torque wrench to avoid over-tightening.
• Reconnect cables and wiring: Carefully reconnect all cables and wiring harnesses, referring to your photos or notes if needed. Ensure that everything is routed correctly and securely.

4. Final Checks and Adjustments:

• Check for proper clearance: Verify that the handlebars have adequate clearance from the fuel tank, body panels, and other components.
• Check the handlebar alignment: Ensure the handlebars are straight and level.
• Check cable function: Test all controls (throttle, brakes, clutch) to verify correct operation.
• Reconnect the battery: Once everything is checked and working properly, reconnect the battery.

5. Test Ride:

• Before undertaking a long journey, test ride the motorcycle on a safe, controlled environment to verify everything functions as expected.

Troubleshooting Common Issues

• Stripped Bolts: If you encounter stripped bolts, try using a bolt extractor or replacing the bolts entirely.
• Tight Cables: If cables are too tight, you might need to adjust cable routing or use cable adjusters.
• Handlebar Alignment: If the handlebars aren't perfectly aligned, carefully loosen the clamps, adjust the position, and re-tighten.

Safety First!

Always prioritize safety. If you're unsure about any step, consult a qualified mechanic. Working on motorcycles can be dangerous; take your time and be meticulous. Improperly installed handlebars can severely compromise safety.

Remember to always refer to your motorcycle's service manual for specific instructions and torque specifications. This guide provides general information; procedures may vary depending on your motorcycle model.